Railway frog repair method and apparatus

ABSTRACT

A railway frog is cleaned, and unsound metal removed therefrom. It is secured on a temperature controlled jig, using clamps and shims to provide a convex camber therein. The jig is in a water tank with the water surface slightly below the lowermost surface or defects of the frog to be repaired. Defects are repaired first, and then a continuous overlay build-up of weld metal is obtained with an automatic welder, until the build-up is sufficient that, after release of the clamps and removal of shims the repaired frog then returns to a straight position and then the built-up tread can be readily ground to provide the exact precision surface required throughout the length of the frog.

[ll] 31,821,840 [45] July 2,1974

United States Patent t191 Kershaw [54] RAILWAY FROG REPAIR METHOD AND Primary Examiner-Charlcs W. Lanham Assistant Examner-D. C. Reile APPARATUS y, lll

[75] Inventor: Ilrlm Knox Kershaw Columbus Attorney, Agent, 0r Firm-Woodard, Weikart, Em-

A hardt & Naughton [73] Assignee: Paul A. Teegarden, Columbus, Ind.

[22] Filed; [57] ABSTRACT Nov. 29, 1972 l BACKGROUND OF THE INVENTION Field of the Invention This invention relates generally to railway trackage, and more particularly to build-up of worn, battered, or otherwise erroded portions of tread, particularly on trackage components such as solid cast manganese steel or manganese frogs, inserts, crossings, guard rails, retarder rails, switch points and the like.

2. Description of the Prior Art Various prior art methods and apparatus for repair of railroad tracks and components are shown and described in patents. Those described in U.S. Pats. of which I am aware are as follows:

Re No. 19,764-Frickey-Nov. 26, 1935 No. 1,924,838-Daley-Aug- 29, 1933 No. 1,933,139-Daley-Oct. 31, 1933 No. 1,976,526--Tracey-Oct- 9, 1934 No. 1,994,479-Lamborn-Mar. 19, 1935 No. 2,018,258-Hartley-Oct- 22, 1935 No. 2,688,180-Mortonet al'-Sept. 7, 1954 Since the most recent of these patents, it has been found that some benefits can be derived by placing a frog in a water tank during welding. However, it has been thought necessary to either cut the frog transversely into pieces to avoid excessive distortion 4 SUMMARY `OF THE INVENTION Described briefly, according to a typical embodiment of my invention, the trackage component (frog, for example), is clamped in a jig, with shimming to provide a convex camber in the component between the ends thereof or between twoportions thereof having lesser cross sectional area than portions in which the build-up operation is to be performed. The lower portion of the component is submerged in non-flammable liquid,

r(typically water) while maintaining 4the surface to be repaired above the surface of the water. The convex camber is also maintained.

Then a build-up operation is performed by the use of an automatic continuous Welder, while the convex camber is maintained by the clampingin the jig. If necessary, successive passes lengthwise are made to provide the necessary amount of build-up, with the weld on successive passes lapping that of previous passes.

After the build-up operation is completed, the shims are removed and the component, in a comparatively unstressed condition, has the built-up surface thereon planed to remove whatever added material is necessary to provide the exact precision surface along the length thereof, for smooth passage of railway car wheels thereover.

The amount of convex camber used is such that after weldingand release ofthe shims or other means establishing the convex camber, the natural reaction of the component to the combined effect of removal of the convex camber establishing means and the thermal stresses remaining due to welding will restore the component to a planar condition of both the built-up material and untreated tread. This will minimize the material removal necessary thereafter for perfecting the exact precision surface of the tread.

It being a known fact that cast manganese can only be heat treated by water quenching, therefore with my process of heat control by immersion in water, there is obtained a continuous quench that effects the hardening of the welds simultaneous with their application.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. l is a perspective view showing a frog in the water tank, and the automatic welder applying the weld metal to the frog, under the scrutiny of the operator.

FIG. 2 is a somewhat schematic diagram of the frog clamped inthe jig, showing the convex camber imparted thereto prior to the build-up operation, and maintained therein during the build-up operation.

FIG. 3' is a cross sectional view through the water tank, with the base plate jig therein, and the frog clamped thereto.

FIG. 4 is a fragmentary side elevational view ofthe tank with a portion brokenvaw'ay to show the frog therein on the base plate.

FIG. 5 is a view of a frog after welding, mounted on a worktable of a precision surface grinding machine.

FIG. 6 is an enlarged fragmentary cross section through a portion of a frog, showing schematically the build-up vand lapping of strips of deposited weld metal.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in detail, FIG. 1l shows the tank 11 mounted on the floor and containing water therein at 12. A railway frog 13 is secured to a base plate 14 (FIG. 3) so that the tread portion 16 of the point on the frog is exposed above the water surface and below the welding'headl 17 of the automatic electric welder. A portion of the welder is shown at 18 and the welding wire spool is shown at I9. The Welder por tion 18, which also supports the spool and the welding head 17, is mounted on a rail 2l extending parallel to the tank l1. Accordingly the welding head can move back and forth in the direction of arrows 23 and 24, lengthwise of the frog. As it does so, it lays down a line or strip of weld metal on the surface of the frog which is to be built-up.

In order to cover the full width of the surface, the welding head can be moved in the direction of arrows 26 and 27, and it is moved in one or the other of these directions in increments by the operator 28 upon completion of each longitudinal pass of the welding machine. In this way, successive strips of weld material are deposited longitudinally with some overlapping of each strip bythe next subsequent strip, as shown somewhat schematically in FIG. 6, at strips 29 and 3l, for example. After completion of a layer of strips, there may be approximately a three-eighth inch wide bead of each strip at the top thereof as indicated at A" in FIG. 6.` During or after each longitudinal pass, the operator will mechanically peen the weld strip to obtain desired work hardening." If there is any flux or slag residue on the strip, he will remove such residue before the next longitudinal passage of the welding head, and before the peening operation. The pipe 32 in FIG. 1 is an exhaust pipe which moves along with the welding head to remove fumes from the work area.

Referring now to FIGS. 3 and 4, the tank itself is supported on a plurality of longitudinally spaced transverse I"beams 33, with suitable angle section reinforcement along the sides as at 34, and elsewhere. A pair of longitudinally extending I beams 36 is supported on the bottom of the tank and these beams extend throughout the length thereof. They are laterally supported near the upper flanges thereof by braces 37 which are secured to the side walls of the tank immediately inside the longitudinal outside bracing angle sections 34.

The frog mounting base plate 14 is affixed to the top of these Ibeams 36. The frog side flange clamp members 38 of FIG. 3 are secured to the base plate by means of studs or bolts passing throughapertures in the base plate, or threadedly received in apertures in the base plate. A suitable hole-pattern is provided in the base plate for adapting it to the clamping thereto of a variety of sizes and shapes of railway frogs. Typically the holes are drilled and tapped for seven-eighth inch diameter S.A.E. bolts. Such bolts are shown at 29, in FIG. 3, and are threadedly received in the base plate, securing the clamps 38 and clamping the frog 13 thereto. Similarly the studs 41 in FIG. 1 are threadedly received in the base plate, and the nuts threadedly received on the tops thereof are used to pull down the clamping bar 42 holding down the one end of the frog. It is preferable to have a clamp securing bolt hole everywhere that a frog may have a flange which can be used for clamping.

According to one feature of the present invention, a non-flammable liquid, typically water, is always maintained in the tank up to a level at or immediately below the upper flanges of the Ibeams 36 in the tank as indicated at wavy line 43 in FIG. 3. The purpose of this is temperature control of the beams 36 to maintain a stable longitudinal dimension `of the beams 36 by means of the comparatively constant temperature of the water in the tank. It' is less susceptible to random fluctuations which might otherwise be caused in the beams by variation in air temperature due to opening and closing of building doors in various types and temperatures of weather. Accordingly, the top flanges of the I beams 36 to which the base plate 14 is affixedv by welding, is quite stable and avoids imparting stresses to the work which might otherwise occur if substantial change in the length of the base plate occurred.

During the actual continuous welding operation, the water level is raised to a line such as shown at 44 in FIG. 3, three-eighths to one-half inch below the dotted line 46 which is the lowerrnost point of the top surface to be repaired and upon which the build-up weld metal is to be deposited. A circulating pump can be employed in the tank to provide circulation of the water during the welding operation, if needed. Normally this is not needed. The volume of the water and the temperature thereof (normally approximately average room temperature), are such as to avoid boiling of the water at the surface, even adjacent the welding operation.

Referring now to the schematic diagram of FIG. 2, the frog 13 is clamped to the base plate, although the clamps are not shown in this instance, in order to schematically show the arrangement of shims and the convex camber obtained. By way of example, where the overall length of a frog is 192 inches, at the points designated by the letters B through H, which are 24 inches apart, the shims can be 0.22, 0.38, 0.47, 0.50, 0.47, 0.38, 0.22 inches respectively. Once welding is completed, and the frog is removed from the base plate, it is expected that the thermal stresses which would otherwise have caused a concave camber, will now return the frog to a condition wherein the top surface thereof is virtually flat and planar, thus minimizing the amount of grinding necessary. Therefore, the height and placement of shims will vary in accordance to length and size of elements to be welded.

After removal from the vat, the frog is placed on and clamped to the table 47 of a precision surface grinding machine 48 of FIG. 5. The table 47 is movable longitudinally on bed 52 in the direction of arrows 49 and 5l. Thus, grinding wheel S3 is movable up and down on the post 54, and in and out by means of a hand crank 56. The wheel is normally left inone adjusted position as the frog is moved by the table longitudinally in the di recton of arrow 49 or 51. Then the hand wheel 56 is turned to move the grinding wheel in or out, for the next pass. The wheel mounting head can also be tipped for grinding sides of the points, flange-way and the guards on the frog.

From start to finish, some of the steps in frog repair are conventional. For example, at the outset, dirt and foreign matter is cleaned from the frog by steam cleaning, mechanical cleaning, wire brushing, chemical soaking, or any combination of these. Then the frog is inspected for flaws, cracks, battered metal, worn areas, or anything detrimental to its function. Then the cracks and battered metals are cut out with a carbon arc gouge and/or other conventional methods, until only sound metal remains. Typically, cracks are beveled to the bottom of the crack. Then all cut metal and grinding dust and slag are removed from the cracks. The water in the tank is lowered to a point below the base plate, about level with the upper flanges of the base plate support beams 36. The frog is-placed on the base plate and secured thereto by the various clamps, clamping the ends with bars such as 42 in FIG. l, if needed, and clamping the frog side flanges with clamps such as 38 in FIG. 3, for example. While so clamping, shims are provided underl the flanges of the frog, entirely across the bottom of the frog, if desired, in suitable thicknesses and at suitable longitudinal spacings to provide a parabolic arc or camber in the frog. The amount and placement of the shims, depend somewhat on experience with frogs of the same type or size and needing the same type of repair. In general, where there is a length of frog between a pair of comparatively thin cross sections, and build-up work is needed along a length of frog between these sections, the parabolc curve should be established throughout the distance between these sections.

Once the water surface has been raised to a level onehalf inch to three-eight-inchs below the bottom of any crack to be repaired, these cracks can be repaired from the bottom up with a stick electrode or with the automatic welder manually operated. As soon as all cracks and the like have been repaired to the point where the only work remaining to be done is surface build-up, then the water surface can be raised to a level one-halt` to three-eighths inch below the lowermost point of the surface on which the build-up is to occur.

Then the automatic welder is moved longitudinally of the frog, laying down a strip of weld metal such as shown at 29 in FIG. 6, for example. After one pass is completed, any slag, flux, or residue is cleaned or This operation continues across the part as from point 57 to point 58 in FIG. 6, for example. Then longitudinal passes can begin for a next layer as at 59, and succeeding longitudinal passes are made, with suitable cleaning and peening after each pass, until the desired amount of build-up is provided to enable grinding the top to a co-planar condition with the rest of the tread of the frog. Usually the dimension A in FIG. 6 between beads at the top of the lap will be'approximately three-eights inch. This will depend somewhat on the l welding head and wire size used.

Once the build-up has been completed, the water level can be lowered to immediately below the base plate. The frog is unclamped and placed on the top of the table 47 of the precision surface grinding machine. There it can be checked for straightness and for the amount of trueing necessary to make it flat for smooth passage of railway car wheels thereover. Then the tread and flange-way sides are ground as needed to provide the smoothness required throughout the tread, and to obtain the required shape of the sides.

Build-up of the point of a frog is typically needed in a frog repair operation, but also it is possible that buildup of the treads, sides, and guards may also be needed. lf can all be accomplished with this same method and apparatus. The same is true for trackage components other than frogs. To facilitate this, rail 2li is mounted to the bridge member 62 secured on posts 611 affixed to opposite ends of the tank. Connectors 63, which can swivel with respect to the rail 2l, and slide transversely of the tank on bridge 62, enable changing the direction of rail 2li somewhat, as indicated by the dotted line 21A in FIG. 7, for example, to change direction of mobility of this self propelled continuous welder, to match the preferred direction of vlaying down the weld strip.

To raise andlower water level, valving between tank lll and a water main and a drain can be used. Other possibilities exist, such as an underground tank 66 from which water can be pumped by pump 6'7 upon opening valve 69 and closing valves 68 and 7l, and to which water can be drained'by opening valve 66 and shutting valve 69. Valve 71 can drain to a sewer.

While the invention has been disclosed and described in some detail in the drawings and foregoing description, they are to be considered as illustrative and not 6 restrictive in character, as other modifications may readily suggest themselves to persons skilled in this art and within the broad scope of the invention.

The invention claimed is:

l. In a method of repairing a tread of an elongated railway trackage component, the combination of steps comprising:

establishing in the component a bend to a convex configuration between the ends thereof;

submerging a lower portion of said component in a non-flammable liquid, while maintaining the surface to be repaired above the surface of the liquid, and while maintaining the bend in said component; and

applying heat and filler material to the surface to be repaired and securing said filler material thereto and thereby building upon said surface while maintaining the bend in said component.

2. The method of claim ll and further comprising the step of:

proceeding lengthwise on said component with said application of heat and filler material thereto and thereby establishing a continuous welded metal overlay on said component.

3. The method of claim 2 wherein said step of proceeding lengthwise is repeated along parallel lines, depositing weld metal in a series of longitudinal strips with some lateral overlapping to provide a homogeneous overlay.

4. The method of claim 3 and further comprising the steps of:

mechanically working said strips; and

superimposing additional layers of strips on the mechanically worked strips by depositing weld metal, and mechanically working strips in each layer before depositing strips in the next layer.

5. The method of claim 2 and further c omprising the steps of:

supplying said liquid in a quantity sufficient to establish the surface thereof within one half inch below the surface to be repaired and avoid boiling of said liquid, an thereby effecting a continuous quench by the liquid to produce a surface hardening of the metal overlay.`

6. The method of claim ll and further comprisingthe steps of:

clamping said component in a jig to establish said bend therein;

and removing externally applied bending stress by unclamping said component after building upon said surface; and

finishing the top of the material built upon the surface.

"7. The method of claim 6 wherein said finishing step is the grinding of the tread to a straight line longitudinally of the component after unclamping of said component. l

6.* The' method of claim 7 wherein:

the step of applying heat and filler material further comprises disposing an automatic electric Welder above the top of said component and moving said welder parallel to the top of said component while applying heat and filler material from said welder to said component.

9. Apparatus for building up and repairing railway components comprising:

a horizontal tank open at the top,

a baseplate horizontally disposed in said tank above the bottom thereof, for mounting the railway component thereto during repair of the component,

said baseplate having means thereon for establishing in the component a bend to a convex configuration between the ends thereof and for maintaining the components in the bend condition during welding,

baseplate support beam means secured to said tank and supporting said baseplate therein, said support beam means including a pair of beams in said tank and affixed to said baseplate, a welding machine which is movable and adapted for applying and securing filler material to the surface to be repaired and built up,

and a non-flammable liquid contained by said tank and covering said base plate and said pair of beams and controlling temperature of said base plate to control dimensions thereof.

10. Apparatus of claim 9 wherein:

said tank and baseplate are substantially longer than` water level above said baseplate. l1. Apparatus of claim 9 and further comprising: a rail extending horizontally over the top of said tank,

said welding machine being mounted on said rail and movable along said rail for welding a railway component when disposed on said baseplate along a path parallel to said rail.

12. Apparatus of claim 1l and further comprising:

rail support means mounted to said tank and supporting said rail over said tank,

said support means including connector means engaging said rail and movable horizontally to enable limited translational and rotational movement of said rail in a horizontal plane and thereby change the direction of mobility of said welding machine with respect to a railway component, when disposed on said baseplate.

13. Apparatus of claim 12 wherein:

said welding machine is a self-propelled automatic continuous Welder.

14. Apparatus of claim l2 wherein:

said tank is elongated, and

said rail support means include a bridge across said tank at opposite ends thereof.

15. The apparatus of claim 14 wherein said component is a railway frog and said means for establishing and maintaining said frog in the bend condition intank for lowering the water surface therein to cludes shim means selectively positioned between said below said baseplate to facilitate mounting and dismounting the frog thereon, and to again raise the frog and said baseplate.

. UNITED STATES PATENT, oFFICE CER'iiFlCA'lE OF CORRECHON PatentNo. 3,821,840 Dated Ju1y2,1974

Inventor(s)m It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Front page, read "Assigneesone-half interest to Paul A,. Teegarden, Columbus, Indiana.

Column 4, line 64, for "eight" read "eighths".

Column 5, line 28, for 4"eights" read "eighths. Column 5, line h3, for "If" read "It".

Column 7, line 27, for "railways" read "railway". s

Signed and sealed this 15th day of October 1974.

(SEAL) Attest:

McCOY M. GIBSON JR. C. MARSHALL DANN Attesting Officer Commissioner of Patents FORM F30-1050 (1Q-69) USCOMMDC 60376-5369 fl LLS. GOVERNMENT PRINTING OFFICE: |969 0366-334.

' UNITED STATES PATENT, OFFICE CERTIFCATE OF CORREKYFION` Patent No. 3 821 840 Dated Juy 2 1974 It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Front page, read "Assignee: one-half interest to Paul A. Teegarden, Columbus, Indiana.

Column 4, line 64, for "eight" read "eighths".

Column 5, line 28, I for "eights" read "eighths".

Column 5, lineA 43, for "If" read "It".

Column line 27, for "railways" read "railway".

Signed and sealed this 15th day of October 1974.

(SEAL) Attest:

McCOY M. GIBSON JR. C. MARSHALL DANN Attesting Officer Commissioner` of Patents FORM Powso (1069) uscoMM-Dc scan-Pes y* U.$A GVERNMENT PRINTING OFFCE: '99 0-365-334. 

1. In a method of repairing a tread of an elongated railway trackage component, the combination of steps comprising: establishing in the component a bend to a convex configuration between the ends thereof; submerging a lower portion of said component in a non-flammable liquid, while maintaining the surface to be repaired above the surface of the liquid, and while maintaining the bend in said component; and applying heat and filler material to the surface to be repaired and securing said filler material thereto and thereby building upon said surface while maintaining the bend in said component.
 2. The method of claim 1 and further comprising the step of: proceeding lengthwise on said component with said application of heat and filler material thereto and thereby establishing a continuous welded metal overlay on said component.
 3. The method of claim 2 wherein said step of proceeding lengthwise is repeated along parallel lines, depositing weld metal in a series of longitudinal strips with some lateral overlapping to provide a homogeneous overlay.
 4. The method of claim 3 and further comprising the steps of: mechanically working said strips; and superimposing additional layers of strips on the mechanically worked strips by depositing weld metal, and mechanically working strips in each layer before depositing strips in the next layer.
 5. The method of claim 2 and further comprising the steps of: supplying said liquid in a quantity sufficient to establish the surface thereof within one half inch below the surface to be repaired and avoid boiling of said liquid, an thereby effecTing a continuous quench by the liquid to produce a surface hardening of the metal overlay.
 6. The method of claim 1 and further comprising the steps of: clamping said component in a jig to establish said bend therein; and removing externally applied bending stress by unclamping said component after building upon said surface; and finishing the top of the material built upon the surface.
 7. The method of claim 6 wherein said finishing step is the grinding of the tread to a straight line longitudinally of the component after unclamping of said component.
 8. The method of claim 7 wherein: the step of applying heat and filler material further comprises disposing an automatic electric welder above the top of said component and moving said welder parallel to the top of said component while applying heat and filler material from said welder to said component.
 9. Apparatus for building up and repairing railway components comprising: a horizontal tank open at the top, a baseplate horizontally disposed in said tank above the bottom thereof, for mounting the railway component thereto during repair of the component, said baseplate having means thereon for establishing in the component a bend to a convex configuration between the ends thereof and for maintaining the components in the bend condition during welding, baseplate support beam means secured to said tank and supporting said baseplate therein, said support beam means including a pair of beams in said tank and affixed to said baseplate, a welding machine which is movable and adapted for applying and securing filler material to the surface to be repaired and built up, and a non-flammable liquid contained by said tank and covering said base plate and said pair of beams and controlling temperature of said base plate to control dimensions thereof.
 10. Apparatus of claim 9 wherein: said tank and baseplate are substantially longer than they are wide; said baseplate is disposed longitudinally in said tank, with its sides spaced from the sides of said tank; said support beam means include a pair of horizontally spaced I section beams supported at the bottom of said tank and having the upper flanges thereof affixed to said baseplate, said baseplate having means thereon for securing railways frogs thereto, and the liquid in said tank is water, and filling and depleating means are associated with said tank for lowering the water surface therein to below said baseplate to facilitate mounting and dismounting the frog thereon, and to again raise the water level above said baseplate.
 11. Apparatus of claim 9 and further comprising: a rail extending horizontally over the top of said tank, said welding machine being mounted on said rail and movable along said rail for welding a railway component when disposed on said baseplate along a path parallel to said rail.
 12. Apparatus of claim 11 and further comprising: rail support means mounted to said tank and supporting said rail over said tank, said support means including connector means engaging said rail and movable horizontally to enable limited translational and rotational movement of said rail in a horizontal plane and thereby change the direction of mobility of said welding machine with respect to a railway component, when disposed on said baseplate.
 13. Apparatus of claim 12 wherein: said welding machine is a self-propelled automatic continuous welder.
 14. Apparatus of claim 12 wherein: said tank is elongated, and said rail support means include a bridge across said tank at opposite ends thereof.
 15. The apparatus of claim 14 wherein said component is a railway frog and said means for establishing and maintaining said frog in the bend condition includes shim means selectively positioned between said frog and said baseplate. 